Augmented-Reality System for Situation-Related Support of the Interaction between a User and an Engineering Apparatus

ABSTRACT

The invention relates to an augmented-reality system having a mobile apparatus for the context-dependent insertion of assembly instructions. The context-dependent insertion of assembly instructions with process-optimized allocation of the necessary work steps provides situation-related support by for work sequences.

FIELD OF THE INVENTION

The invention relates to an augmented-reality system forsituation-related support of the interaction between a user and anengineering apparatus. Such a system and method may be used in the fieldof automation technology, for production machinery and machine tools, indiagnostic/service support systems, and for complex components,equipment and systems, such as vehicles and industrial machinery andinstallations.

BACKGROUND OF THE INVENTION

GB 2 327 289 discloses a work-support apparatus which uses a displaywhich allows an assembly line worker to simultaneously visualizeinstructions relating to the work to be carried out and informationabout results of this work. The results of the work are recorded bymeasuring means, or by the worker entering a specific part number, withthe work process being recorded by one or more cameras.

SUMMARY OF THE INVENTION

The present invention provides a system and a method which, in concreteoperating situations, permit rapid and reliable support for a user in asimple and cost-effective manner. Further, the invention is based on theinsight that the user of an engineering apparatus generally needs tocomplete certain training sessions before he is able to carry out morecomplex engineering work, such as producing an intermediate and/or finalproduct up to assembling a car. Process-optimized use of such anoperator can be achieved where the operator is supported by anaugmented-reality system related to the relevant process situation. Inthis context, real information, for example the initial state of a partwhich is to be produced, is recorded and the system uses this toascertain, in context-dependent fashion, the coming work sequences forthe user and displays them for the user in a mobile apparatus.

In particular in NC-controlled applications, the opportunity to insertsimulation data provides further additional support for the worker. Inthis context, the augmented-reality system can be used to overlaycomputer-generated visualizations on real information based on simulateddata. This provides support for setting up numerical control, a.k.a.NC-controlled processes/applications.

In a preferred embodiment of the present invention, documentation datais either static or dynamic information data. Examples of staticinformation are engineering data from handbooks, exploded drawings,maintenance instructions, etc. Examples of dynamic information areprocess values such as temperature, pressure, signals, etc.

In a further preferred embodiment of the invention, rapidsituation-related access to the documentation data is provided by arecording means having an image-sensing apparatus. An evaluation meansfor evaluating the real information such that an object of thedocumentation data may be ascertained from the real information, and bya visualization means for visualizing the documentation data. Rapidsituation-related access to the documentation data is further supportedby virtue of the recording means being user-controlled and being, inparticular, in the form of voice-controlled recording means and/orrecording means controlled by control data.

Augmented-reality techniques on the basis of the static and/or dynamicdocumentation and/or process data can be used in a manner which isoptimal for a large number of applications by virtue of the recordingmeans and/or the visualization means being in the form of data goggles.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described in greater detail and explained belowusing the exemplary embodiments shown in the drawings, in which:

FIG. 1 illustrates a block diagram of a first exemplary embodiment of anaugmented-reality system;

FIG. 2 illustrates another block diagram of an exemplary embodiment ofan augmented-reality system; and

FIG. 3 illustrates an application example of situation-related access toexpert knowledge and/or documentation data.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a basic illustration of an augmented-reality system fortransmitting first information data from a first location O1 to a remotesecond location O2 of an expert in order for a user at the firstlocation O1 to be supported by the remote expert at the second location,for example in the case of servicing and/or repair. The user, who is notshown in FIG. 1, is equipped with mobile equipment 4, 6. The mobileequipment 4, 6 comprises data goggles 4 holding a video camera 2 and amicrophone 11. The data goggles are coupled to a device for wirelesscommunication, for example a radio transceiver apparatus 6 which cancommunicate with the automation system A1-An via a radio interface 15.The automation system A1-An can be coupled by means of a data link 14 toan augmented-reality system 10, which is also referred to as “ARsystem”. The AR system contains an information module 1 b for storing oraccessing information data, an AR base module 8, and an AR applicationmodule 9. The AR system 10 can be connected to the Internet 5 by meansof a data link 13, with an internet connection 12 (shown by way ofexample) permitting access to further memory and documentation data 1 a.

When equipped with the data goggles 4, and the mobile radio transmissiondevice 6, a worker can move freely in the installation A1-An formaintenance and servicing purposes. If, by way of example, maintenanceor repair of a particular subcomponent in the installations A1-An isnecessary, the camera 2 on the data goggles 4 is used, possiblycontrolled by voice commands recorded by the microphone 11, to set upappropriate access to the relevant documentation data 1 a, 1 b. Theradio interface 15 is used to set up a data link to the installationA1-An or to an appropriate radio transmission module, and to transmitthe data to the AR system 10. In the AR system, the data obtained fromthe user are evaluated in relation to the situation, and informationdata 1 a, 1 b are accessed automatically or under interactive control bythe user. The relevant documentation data la, lb ascertained aretransmitted to the radio transmission device 6 via the data links 14,15, and, on the basis of the operating situation recorded. An analysisis thus performed which is the basis of the selection of data from theavailable static information. This results in situation-related,object-oriented or component-oriented selection of relevant knowledgefrom the most up-to-date data sources 1 a, 1 b. The information isdisplayed using the respective visualization component such as ahand-held PC or data goggles. The user is thus provided in situ withonly the information needed. This information is always at the mostup-to-date level and accordingly, the service technician is notoverloaded with unnecessary or out-of-date information.

FIG. 2 shows another application example of a system for documentationprocessing for servicing and maintenance. The system comprises anaugmented-reality system 10 which contains an information module 1 b forstoring information data, an AR base system 8 and an AR applicationmodule 9. The AR system 10 can be coupled to the Internet 5 by means oflink lines 13, 18. From the Internet, an illustrative data link 12 canbe used to connect to a remote PC 16 with a remote expert 22. Theindividual modules of the AR system 10 are coupled together by means ofconnections 19, 20, 21. The communication between a user 7 and the ARsystem takes place via interfaces 8, 23. The AR system can be coupled toa transceiver apparatus which permits two-way data communication betweenthe AR system 10 and the user 7, using data goggles 4, either directlyvia the interface 8, or via an interface 23 using a radio transceiverdevice 17, located in the area of the user 7. The connection 23 can beproduced using a separate data link or using the electricity mains inthe form of a “power-line” modem. Besides a display apparatus in thearea of the goggle lenses, the data goggles 4 contain an image-sensingapparatus 2 in the form of a camera, as well as a microphone 11. Theuser 7 can move throughout the installations A1-An using the datagoggles 4 and can carry out servicing or maintenance work.

The data goggles 4 and the corresponding radio transceiver apparatuses,for example the radio transceiver apparatus 17 worn by a worker, have aprophylactic functionality in that the respective operating situation isrecorded, for example by the camera 2, or by localization by the staff7. On the basis of the recorded operating situation, the AR systemselects data for the installation A1-An being maintained. Thefundamental advantage of the system shown in FIG. 2 is that this systemsupports the interaction of the individual single functionalities on anapplication-related basis. Thus, a concrete operating situation is firstrecorded automatically and this operating situation is then analyzed,with the currently relevant aspects being automatically ascertained fromthe most up-to-date, available static information in combination withthe presently recorded dynamic data. Accordingly, assembly instructions,for example, are correlated to current process data. This provides thework staff 7 with a situation-related display of the relevantinformation, by means of an overlayed visualization of the appropriatedata such that the real operating situation is extended by theascertained information in the field of view of the staff. This quicklyequips the staff 7 to take action, and hence safeguards necessarymachine execution times. The maintenance technician 7 can also obtainsupport in situ from the remote expert 22 and the knowledge 16 availableat the location of the remote expert 22.

FIG. 3 shows an application example of situation-related access todocumentation data. FIG. 3 shows a first screen area B1 showing aninstallation component. The right-hand screen area B2 shows a user 7looking at an individual installation component, for example. The user 7is equipped with data goggles 4 containing a camera 2. The data goggles4 additionally hold a microphone 11 and a loudspeaker 16. The left-handscreen area B1 shows a view of pipelines which can be observed using thedata goggles shown in the image window B2. In the left-hand screen areaB1, two points P1, P2 are marked which represent two image detailsobserved using the data goggles 4. After observation of the first pointP1 (the pipeline arranged in the area of the point P1), additionalinformation is visualized in the data goggles 4 for the user 7. Thisadditional information I11 comprises documentation data for the firstpoint P1 which contain work instructions for this pipeline, and for thepoint P2 contain the installation instruction to be carried out in asecond step. In this case, the installation instruction results in theuser 7 being informed of the torque and the direction of rotation of thescrew connection at the point P2 by means of visualization of thesupplementary data I12. The user 7 thus very quickly obtains asituation-related instruction for the object being observed. If anintelligent tool is used which is capable of recording the torquecurrently being used, it is also possible for the user to be instrucedto increase or decrease the torque appropriately on the basis of thecurrent torque.

Further background information is provided below on the fields of use ofthe present invention. Application-oriented requirement analysis anddevelopment of AR-based systems are useful in supporting work processesin development, production and servicing of complex engineeringproducts, installations in fabrication and process technology, servicesupport systems, as in the case of motor vehicles, or for maintenance ofany engineering equipment.

Augmented reality, “AR” is a novel type of man-machine interaction withgreat potential for supporting industrial work processes. With thistechnology, the observer's field of view is enriched withcomputer-generated virtual objects, which means that product or processinformation can be used intuitively. Besides the very simpleinteraction, the use of portable computers opens up AR applicationfields with high mobility requirements, for example if process,measurement or simulation data are linked to the real object.

Today German industry is characterized by increasing customerrequirements in terms of individuality and quality of products and bythe development processes taking substantially less time. Especially indeveloping, producing and servicing complex engineering products andinstallations, it is possible, by means of innovative solutions toman-machine interaction, both to achieve increases in efficiency andproductivity and to design work so as to enhance competence andtraining, by the user's need for knowledge and information beingsupplied in a situation-related manner on the basis of up-to-date data.

Augmented reality is a technology with numerous innovative fields ofapplication:

-   -   In development for example, a “mixed mock-up” approach based on        a mixed-virtual environment can result in a distinct        acceleration of the early phases of development. Compared with        immersive “virtual reality” (VR) solutions, the user is at a        substantial advantage in that the haptic properties can be        depicted faithfully with the aid of a real model, whereas        aspects of visual perception, e.g. for display variants, can be        manipulated in a virtual manner. In addition, there is a major        potential for user-oriented validation of computer-assisted        models, e.g. for component verification or in crash tests.    -   In flexible production, it is possible, inter alia, to        considerably facilitate the process of setting up machinery for        qualified skilled workers by displaying, e.g. via mobile AR        components, mixed-virtual clamping situations directly in the        field of view. Fabrication planning and fabrication control        appropriate to the skilled worker in the workshop is facilitated        if information regarding the respective order status is        perceived directly in situ in connection with the corresponding        products. This also applies to assembly, with the option of        presenting the individual work steps to the assembler in a        mixed-virtual manner in the actual training phase. In this        connection, it is possible, e.g. by comparing real assembly        procedures with results of simulations, to achieve comprehensive        optimizations which both improve the quality of work scheduling        and simplify and accelerate the assembly process in the critical        start-up phase    -   Finally, regarding servicing, conventional technologies are by        now barely adequate for supporting and documenting the complex        diagnostic and repair procedures. Since, however, these        processes in many fields are in any case planned on the basis of        digital data, AR technologies provide the option of adopting the        information sources for maintenance purposes and of explaining        the dismantling process to an engineer, e.g. in the data        goggles, by overlaying real objects. Regarding cooperative work,        the AR-assisted “remote eye” permits a distributed problem        solution by virtue of a remote expert communicating across        global distances with the member of staff in situ. This case is        particularly relevant for the predominantly medium-sized machine        tool manufacturers. Because of globalization, they are forced to        set up worldwide production sites for their customers. However,        it is not practical to have a presence in all the important        markets, nor is it possible to dispense with the profound        knowledge of experienced service staff of the parent company        with respect to the increasingly more complex installations.    -   The special feature of man-machine interaction in augmented        reality is the very simple and intuitive communication with the        computer, supplemented, for example, by multimode interaction        techniques such as voice processing or gesture recognition. The        use of portable computer units additionally enables entirely        novel mobile utilization scenarios, with the option of        requesting the specific data at any time via a wireless network.        Novel visualization techniques permit direct annotation, e.g. of        measured data or simulation data, to the real object or into the        real environment. In conjunction with distributed applications,        a number of users are able to operate in a real environment with        the aid of a shared database (shared augmented environments) or        to cooperate in different environments with AR support.

Augmented reality has been the subject of intense research only in thelast few years. Consequently, only a few applications exist, either atthe national or the international level, usually in the form ofscientific prototypes in research establishments.

-   -   U.S.A.: As with many novel technologies, the potential uses of        augmented reality were first tapped in North America. Examples        include cockpit design or maintenance

of mechatronic equipment. The aircraft manufacturer Boeing has alreadycarried out initial field trials using AR technology in the assemblyfield. The upshot is that in this hi-tech area too, the U.S.A. occupiesa key position, potentially making it a technological leader.

-   -   Japan: Various AR developments are being pushed in Japan, e.g.        for mixed-virtual building design, telepresence or        “cyber-shopping”. The nucleus is formed by the Mixed Reality        Systems Laboratory founded in 1997, which is supported jointly        as a center of competence by science and by commerce and        industry. Particular stimuli in the consumer goods field are        likely in the future from the Japanese home electronics        industry.    -   Europe: So far, only very few research groups have been active        in Europe in the AR field. One group at the University of Vienna        is working on approaches to mixed-real visualization. The IGD        group, as part of the ACTS project CICC, which has now come to        an end, has developed initial applications for the building        industry and a scientific prototype for staff training in car        manufacturing.

Thus the invention should be seen in particular in the context ofspecific fields of application, including “production machinery andmachine tools” (NC-controlled, automation-technology processes), and“diagnostics/service support systems for complex engineeringcomponents/equipment/systems” (e.g. vehicles, but also industrialmachinery and installations).

The order of the work steps is improved by means of “appropriate”perception of environment and situation. The respective combination ofwork environment, process situation, progress of the activity andknowledge of the staff is utilized to relativize the next succession ofinstructions. The basic idea is context-dependent insertion of assemblyinstructions with process-optimized allocation of the necessary worksteps. The conceivable optimization can have parameters set for it, e.g.in terms of particular resource use (time, material, cost etc).

In summary, the invention relates to an augmented-reality system havinga mobile apparatus for context-dependent insertion of assemblyinstructions. The context-dependent insertion of assembly instructionswith process-optimized stipulation of the necessary work steps providessituation-related support by for work sequences. In addition, furthersupplementary instructions relating to the respective operatingsituation can be inserted for the user, for example on the basis ofparticular assembly steps etc., i.e. in the case of a firmly prescribedassembly procedure. Thus, by way of example, preventive maintenanceinstructions etc. can be given in context-dependent fashion withoptimization of the timing and process.

1-10. (canceled)
 11. A situation-related support system for theinteraction between a user and an apparatus comprising: mobile equipmentcomprising a video camera for providing images of at least parts of theapparatus and a display, a device for wireless communication coupledwith said mobile equipment, an augmented reality system comprising meansfor an analysis of video images which have been recorded by the videocamera and have been wirelessly transmitted by the device for wirelesscommunication to the augmented reality system, means for accessingdocumentation data and for ascertaining relevant data from saiddocumentation data depending on the analysis, and means for transmittingthe relevant data to the device for wireless communication, wherein thedisplay in the mobile equipment displays the relevant data.
 12. Thesystem according to claim 11, wherein the apparatus is an industrialinstallation.
 13. The system according to claim 12, wherein theindustrial installation comprises a further device for wirelesscommunication and a communication means coupled with said augmentedreality system.
 14. The system according to claim 11, wherein the mobileequipment further comprises a microphone and wherein the relevant datais accessed under interactive control by a user via said microphone. 15.The system according to claim 11, wherein the display is located onlenses of data goggles, the recording means is an image-sensingapparatus located on the data goggles, and a microphone is located onthe data goggles.
 16. A situation-related support method for interactionbetween a user and an industrial installation, comprising the steps of:recording video images of at least a part of said industrialinstallation by a mobile equipment comprising a video camera and adisplay, wirelessly transmitting the video images to said industrialinstallation, transmitting said video images from the industrialinstallation to an augmented reality system; analyzing the video imagesin the augmented reality system, accessing documentation data in theaugmented reality system, ascertaining relevant data from saiddocumentation data depending on the analysis, transmitting the relevantdata to the device for wireless communication, displaying the relevantdata within the mobile equipment.
 17. The method according to claim 16,wherein the step of ascertaining relevant data is further controlled byvoice commands recorded by a microphone arranged within the mobileequipment.
 18. The method according to claim 16, wherein the display isarranged in data goggles and provides additional information in a fieldof view of a user and wherein the relevant data are overlayed in thefield of view of the user.
 19. The method according to claim 16, whereinthe step of accessing documentation data comprises the step of accessinga remote data base or a remote expert.
 20. A method for providingsituational support to a user, comprising: determining an industrialinstallation which requires service or repair; recording video images ofa component of the industrial installation; wirelessly transmitting thevideo images to an augmented reality system; analyzing the video imagesand accessing documentation data for said component depending on theanalysis; determining from said documentation data a context-dependentinstruction sequence; and displaying the context-dependent instructionsequence such that the user may view the context-dependent instructionssubstantially simultaneously with the component of the industrialinstallation.
 21. The method of claim 20, further comprising anintelligent tool operated by the user, wherein the method furthercomprises the step of receiving information from said intelligent tooland instructing the user how to operate said intelligent tool.
 22. Themethod of claim 20, wherein the step of analyzing the video imagescomprises the step of determining at least one point of said industrialinstallation within an video image and displaying instructions in afield of view of the user relating to said one point.
 23. The method ofclaim 22, wherein said instructions are displayed in a window and agraphical connection is drawn from said window to said one point.